铝挤压机培训资料31Word文档格式.docx
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金属网制的),bar(木、金属等的条),section,hollowsection,andwideflatsections
b.Copper(铜)andcopperalloysincludingbrass(黄铜)(heavymetal)easytoextrudeand/ordifficulttoextrude.Wire,bar,andsection
c.Steelandhigh-strengthsteelalloyseasytoextrudeand/ordifficulttoextrude.
●Processtechnology
a.Extrusionwithoutlubrication(润滑)andwithoutashell(壳)
b.Extrusionwithoutlubricationandwithashell
c.Extrusionwithlubricationwithoutashell
●Tooling
a.Container(挤压筒),stem(杆),dummyblock(挤压垫),anddie
Thewiderangeofdifferentdesignsforextrusionpresseshasrecentlybeenreducedinmostextrusionplantstoafewhigh-output(高输出)types.
Therefore,onlyextrusionpressdesignsthatdominate(主导)today’smarketarediscussedinthischapter.ThesearereferredtoasstandardextrusionpressesinTable3.1.
Direct-extrusionpressesaccountformorethan95%ofthetotalvolumeofallpresses.Thedirect-extrusionpressisusedforallcurrentextrusionprocesses.
Table3.1Pressesforthedirectextrusionofaluminumalloys(lightmetal),copperalloys(heavymetal),andsteel
Machinesforthedirecthotextrusionoflight-metalalloysaremainlyusedfortheextrusionofsection(80%),tube(10%),androd(<
10%)inaluminumandaluminumalloys.Themachinesfordirecthotextrusionofheavymetals,mainlycopperandcopperalloys,areusedfortheextrusionofrod,wire,andsection(60%)(mainlyinbrass)andtube(40%)(mainlyincopper).
Steelandsteelalloysareonlyproducedbyextrusiontoalimitedextent(围,程度),andthenonlywhenrolling(滚压;
轧制)isnotpossibleorthevolumesaretoosmall.
Thefollowingmajorpointsmustbeconsideredintheconstructionofextrusionpresses:
●Technologyrequirements:
Thiscoversthemetallurgical(冶金的,冶金学的)aspectsofthedeformationtechnologyofextrusion.
●Economicfactors:
Theeconomicneedforrationalization(合理化)intheconstructionofextrusionpressesismostclearlyseeninaluminumextrusion.Newextrusionplantsarebuiltasintegrated(整合的)productionlines.Theyincludebilletstores,billetheating,extrusionpress,handlingequipmentwithlongitudinal(纵向的)andtransverse(横向的)conveyors(输送带),sectioncoolingsystems,stretcher(拉伸机),cut-to-lengthsaws(定长剪切锯床)andstackers(栈式存储器),aswellasheattreatmentequipmentandpacking(包装)lines.Similardevelopmentscanbefoundinheavy-metalextrusionplants.Sophisticated(富有经验的;
精致的;
复杂的)systemsforelectronicdatacollectionanddataanalysisfortheeconomicoptimalproductionarealreadyconsideredtobestandard.
Wire['
waiə]金属丝制的;
金属网制的
bar[bɑ:
](木、金属等的)条
Copper['
kɔpə]铜
brass[brɑ:
s]黄铜
lubrication[,lu:
bri'
keiʃən]润滑
shell[ʃel]壳
Container[kən'
teinə]挤压筒
stem[stem]杆
dummy['
dʌmi]block[blɔk]挤压垫
high-output高输出
extent[iks'
tent]围,程度
rolling['
rəuliŋ]滚压;
轧制
metallurgical[,metə'
lə:
dʒikəl]冶金的,冶金学的
rationalization[,ræ
ʃənəlai'
zeiʃən]合理化
integrated['
intigreitid]整合的
longitudinal[,lɔndʒi'
tju:
dinəl]纵向的
transverse[træ
nz'
və:
s]横向的
conveyors[kən'
veiə]输送带
stretcher['
stretʃə]拉伸机
cut-to-lengthsaws定长剪切锯床
stackers['
stæ
kə]栈式存储器
packing['
pæ
kiŋ]包装
Sophisticated[sə'
fistikeitid]富有经验的;
复杂的
3.1.1ExtrusionPressDesignPrinciples
Initialdiscussions,over50yearsago,torationalizetheconstructionofextrusionpresses,resultedinthestandardizationofextrusiontoolingin(DIN24540).Withinthelast30years,thepressmanufacturingcompanieshaveintroducedstandardizeddesignsontothemarket.
Table3.1showsthefeaturesofextrusionpressesforlightmetals,heavymetals,andsteel.
Themainfeatureofthedirect-extrusionpressisthestationarycontainerduringextrusion.Thedie,whichisalsostationary,andthesupporttoolingarelocatedatoneoftheendfacesofthecontainer,infrontofthecontainerbore((管、圆筒的)空心部分,膛孔).Oppositethedie,thedummyblocklocatedinfrontoftheextrusionstempushesthebilletthroughthecontainerbore,andthesectionemerges(形成,出现)throughthedie(Fig.3.1).
Fig.3.1Toolarrangementfordirectextrusion
Fig.3.2Geometricrelationshipsfordifferentdesignsfordirectextrusion
Thegeometricproportions(比例;
大小)fordifferentdesignsfordirectextrusionareshowninFig.3.2.
Themostcommondesignofextrusionpresstodayistheprestressed(预应力的)four-columnpress(四柱压力机).Itisusuallybuiltwithastandardstroke(行程,冲程),whichprovidesgoodaccessandeasymaintenance(维护,保持,维修).
Inastandard-strokepress,thebilletisloadedbetweenthecontainerandthestem.Thepressstrokeisdeterminedbytheloadingstrokeandtheextrusionstroke.Therearenospecificrequirementsplacedonthequalityofthebilletgeometry;
itisnotimportantforthebilletloading.Over95%ofextrusionpressesinextrusionplantsarestandard-strokes.
Figure3.3showsa75MNaluminumextrusionpresswithextrusiontoolingfortheextrusionofroundandflatbillets.ThemovingcrossheadhasX-guidingsimilartothecontainerholder.Thecontrolandinformationsystemstomonitor(监视,监听,监督)andoptimize(使最优化,使完善)theextrusionprocesscanbeseenintheforeground(最显著的位置).
Fig.3.3Standardstrokeextrusionpress.Location:
AlusuisseinChippis,Switzerland
Theshort-strokepressiscompact(紧凑的,紧密的,简洁的)andrequireslessspace.Theshortstroke(approximately60%ofthestandardstroke)includestheextrusionstrokeandafreestrokeformanipulation(操作;
操纵;
处理).Therearethreedifferentdesigns.
Thebillet-loadingrequirementsareeither:
●Billetloadingwithabilletloaderinthefreespacebetweenthedieandthecontainer,withthebilletclamped(夹住,夹紧)onthepresscenterline(themostcommondesign)
●Freespacebyextrusionstemtransversemovementonthemovingcrosshead(billetloadingwithabilletloaderbetweenthemovingcrossheadandthecontainer)
●Threecontainersthatcanberotated(旋转)aroundacolumnofthepressframe(框,结构,骨架)(billetloadingwithoutabilletloaderinoneofthethreecontainersoutsidethepress)
Fig.3.4Short-strokepress(compactpress)fordirectextrusion
Figure3.4showsthecontroldesk,movableauxiliary(辅助的)controldesk(swinging(旋转的)),hotlogshear(圆棒剪)withthebilletloader,andtheshort-strokepressforaluminumalloys.Thecontainerisintheextrusionposition.Thebilletisloadedbetweenthedieandthestemwhenthecontainerhasmovedbackoverthestem.Thebilletmustbeheldexactlybetweenthedieandthestemonthepresscenterline.Thisensuresthattheclearancebetweenthebilletandthecontainerisasuniformaspossible,guaranteeingperfectupsetting(缩锻,镦锻)ofthebilletinthecontainer.
Thetolerance-relateddiametervariationsmustbecompensated(补偿)bythebilletloadertoensurethatthebilletcanbeclampedonthepresscenterline(Fig.3.5).Thisensuresthattheupsettingofthebillettakesplaceunderoptimalconditionsbecauseoftheequalclearanceonallsidestothecontainerbore.Airinclusionsarelesscritical,andtransverseforces,evenifacceptabletoasmalldegree,areavoidedduringupsetting.
Fig.3.5Upsettingofabilletclampedonthepresscenterline(good),andupsettingofabilletrestinginthecontainer(poor)
Short-strokeextrusionpresseshavebeenthestateoftheartforsometime.Therearevariousreasonsforthis.Schloemannbuilttwo125MNrod-and-tubeextrusionpressesforaluminumaroundapproximately1950.Theseweremanufacturedasshort-strokepressesforproductionreasons,withbilletloadingbetweenthedieandthecontainer.Thestemtransversemovementwasusedbeforetheendofthelastcentury.Thelengthofexpensivepresscomponents,includingcolumnsandthemaincylinder,canbekepttoaminimum.
ThecompanyLoewybuiltasteeltubeextrusionpressin1960,withthreecontainersthatcouldberotatedaroundacolumn.Theaimwashigh-throughput(高生产量)extrusionwithfastpresscycles.Inpractice,thiswasunsuccessful.Themanipulationoftheheavyheatedcontainerswasonlypossiblewithexpensivetechnology.Temperaturevariationswithinthecontainerholderaswellasinadjacent(毗连的,邻近的,接近的)presscomponentscouldnotbeavoidedduringproduction.Accuratelocationoftherotatingcontainersonthepresscenterlineandinlinewiththestemandthediecouldnotbeguaranteedtothenecessaryreproducibility.Thecontinuousmovementofthelargecontainers,threerotationsof120º
withinanextrusioncycle,requiredextensivemaintenanceandregularrepair.Onlyafewpresseswerebuilttothisdesignandactuallyusedforproduction.Ingeneral,short-strokepressesaremoreexpensivethanstandard-strokepressesbecauseofthemanipulationneededforbilletloadingandthemechanicaldesign.
bore[bɔ:
](管、圆筒的)空心部分,膛孔.
emerges[i'
mə:
dʒ]形成,出现
proportions[prəu'
pɔ:
ʃən]比例;
大小
prestressed[pri:
'
stres]预应力的
four-columnpress四柱压力机.
stroke[strəuk]行程,冲程